Cutting tool

ABSTRACT

An oblique edged cutting tool comprises a holder at the front end of which is formed an inclined surface on which a tip is detachably mounted by means of an attaching member. The tip to be used is of an indexable throw-away type having an outer configuration radially symmetrical about its geometric center and the tip is provided with a curved cutting edge on the outer periphery thereof. The tip is attached to the holder of the oblique edged cutting tool so that the tip is positioned so that the curved cutting edge of the tip projects outwardly towards the surface of a work to be machined.

This is a continuation-in-part-application of U.S. patent applicationSer. No. 657,126 filed 10-3-84 now U.S. Pat. No. 4636117 issued 1/13/87.

BACKGROUND OF THE INVENTION

This invention relates to an oblique edged cutting tool provided with ashank portion to a front end of which a flat cutting tip of an indexablethrow-away type having an outer configuration radially symmetrical aboutits geometric center is detachably attached.

In the art of this field, a work is generally cut to obtain a finelymachined surface by a cemented carbide cutting tool with highspeed-minute feed cutting amount or by a high speed steel tool such as aspring tool with low speed-high feed cutting, and in a rare case, anoblique edged tool is utilized at relatively high speed and withrelatively high feed cutting amount as shown in FIGS. 1 and 2.

In FIGS. 1 and 2, the oblique edged tool 1 is generally made of a highspeed steel and the cutting edge of the tool is integrally formed with aholder 3, which is referred to herein as a holder or shank of the tool.The inclination α of the cutting edge is usually selected in a range of45°˜70°.

FIG. 3 is a perspective view showing cutting condition in use of theoblique edged tool 1 shown in FIGS. 1 and 2, in which the oblique edgedtool 1 which is fed at a feeding amount f with respect to a work 4rotating with the revolution numbers N performs a cutting operation incontact with a point P of the cutting edge positioned in the same levelof an axis O-O' of the work. In FIG. 3, the inclination i is determinedby a line m which is the extension of the cutting edge of the obliqueedged tool 1 and a line l normal to a cutting velocity direction V(hereinafter may be called merely cutting direction) at the point P ofthe cutting edge, and in a usual cutting operation in use of a lathe,the direction of the line l substantially accords with the feedingdirection of the tool.

However, with the oblique edged tool 1 of the type described above, itis required to regrind the cutting edge 2 every time the cutting edge 2wears, and after the cutting edge is reground several times, it isnecessary to finally dispose of the holder 3 itself, which is noteconomical.

An oblique edged tool 5 as shown in FIG. 4 has been proposed forobviating the disadvantages described above, in which a tip 6 providedwith a cutting edge 7 is detachably fitted to the holder 3 through akeep member 9. Although the tip 6 adapted for the oblique edged tool 5is provided with two or more cutting edges 7, even a specifically maderectangular tip 6 can provide only four cutting edges 7 defined by thelongitudinal four edges of the rectangular tip 6. For this reason, it isrequired to provide a tip having a lot of cutting edges for the purposesof reducing tip exchanging times and using economically cutting edges.However, in comparison with a non-oblique edged tool with an indexablethrow-away type standard tip (a tip made in accordance with ISO,International Organization for Standardization, called hereinaftermerely a standard tip), the oblique edged tool 5 with the specificallymade rectangular tip 6 seems at a glance to have a long cutting edge 7contacting the work, so that the application of indexable throw-awaytype standard tips widely used in tip manufacturing makers to an obliqueedged tool is not considered up to today's standard. Moreover, thespecifically made rectangular tip 6 can be manufactured from a limitednumber of substances and is not economical in comparison with thestandard tip. Furthermore, the keep member 9 for keeping the tip 6 tothe holder 3 projects over the holder surface, so that it is difficultfor an operator to observe the cutting edge 7 during the cuttingoperation. In addition, when the bolt 8 is excessively rotated, there isa fear of falling down the keep member 9, thus adversely affecting thecutting operation.

In another aspect of the prior art of cutting tool having a rod-likeshank portion to a front end of which a cutting tip made of a cementedcarbide or ceramics is attached has widely been used for a various kindsof machine tools such as a lathe, boring machine and a shaping machine.In a well-known art as shown in FIGS. 5 and 6, a tip 102 is fixed byusing a pin or lever, to the front end of a shank 101 of a cutting tool.FIG. 5 shows a cutting condition in which an outer peripheral surface ofa rod-like work 103 is cut and FIG. 6 also shows a cutting condition inwhich an end surface of a disc-like work 103 is cut. In FIGS. 5 and 6, aletter N designates a rotating direction of the work 103 and a letter fdesignates a feeding direction of a cutting tool. In the use of acutting tool of the type shown in FIG. 5 or 6, a work is cut by a noseportion 104 between a front edge and side edges of the tip 102, so thatit was likely to damage or wear the nose portion 104, and moreover, insome cases, the tip 102 is disposed of without utilizing a portion ofthe tip other than the nose, thus being not economical. In addition, thenose portion 104 is designed to have a relatively small radius forpreventing undesirable chatter vibrations at the cutting time. For thisreason, when the feeding amount of the cutting tool increases, thesurface of the work is roughly finished or machined and when the feedingamount decreases, the cutting efficiency is lowered. Generally, degreeof finishing roughness H_(o) of the work 103 is represented by thefollowing equation,

    H.sub.o =F.sup.2 /8r

where f is a feeding amount per one rotation of the work and r is radiusof the nose portion.

Furthermore, in a case where the tip 102 is made of a material havinghigh hardness such as cemented carbide, ceramics or cermet, a rake anglecannot be set to be large, so that the cutting condition is degraded andthe cutting resistance increases thereby not to perform a fine cut-inoperation. The increasing of the cutting resistance generates a highcutting heat which results in undesirable thermal expansion of thecutting tool or the work thereby not to attain a high workingperformance. In addition, in a case where the work is cutintermittently, the nose portion of the tip is likely damaged and manyburrs are formed.

SUMMARY OF THE INVENTION

A main object of this invention is to eliminate defects or disadvantagesof a conventional cutting tool and provide an improved oblique edgedcutting tool provided with increased numbers of cutting edges and alsoprovided with an easily detachable tip at the inclined front endthereof.

Another object of this invention is to provide an improved oblique edgedcutting tool which can operate so as to obtain a fine machined surfaceof a work even when the tool is fed with a relatively high feed amountwithout substantially generating burrs, and which can also operate suchthat a tip detachably attached to the tool is less damaged in anintermittent cutting operation.

A further object of this invention is to provide an oblique edgedcutting tool which is provided with a tip which is an indexablethrow-away type tip having outer configuration radially symmetricalabout its geometric center, the tip being detachably attached to theinclined front end of the tool so that the cutting edge of the tip issubstantially parallel or normal to the surface of a work to be machinedwith a slight angle.

According to this invention, for achieving the above objects, there isprovided an oblique edged cutting tool comprising a holder having afront end provided with an inclined surface, a flat tip to be detachablyattached to the front end of the holder, the flat tip being of anindexable throw-away type having outer configuration radiallysymmetrical about the geometric center thereof, and means for detachablyattaching the flat tip to the inclined surface of the front end of theholder, the flat tip being provided with a cutting edge on the outerperipheral surface thereof and the cutting edge being inclined by apredetermined angle with respect to the cutting relocity direction ofthe oblique cutting.

In one aspect of this invention, the flat tip has a straight cuttingedge on the outer peripheral surface thereof and the tip is attached tothe holder so that the upper and lower flat surface of the tip aresubstantially parallel or normal to the surface of a work to bemachined.

Another aspect of this invention is that the flat tip is provided with acurved cutting edge on the outer peripheral surface thereof and the flattip is attached to the holder so that a tangential line at theintermediate point of the curved cutting edge and a line normal to thecutting velocity direction of oblique cutting of the cutting toolconstitute a predetermined angle and that the upper and lower surfacesof the flat tip are substantially parallel or normal to the surface of awork to be machined.

According to the oblique edged cutting tool of this invention, in oneaspect, since an indexable throw-away type tip, such as standard tipbased on ISO, can be used, the number of cutting edges are increased,and there is no need for using a specifically made tip. In anotheraspect, since the tip provided with a curved cutting edge is attached tothe holder of the cutting tool with a relief angle with respect to asurface of a work to be machined, the fine machined surface is obtainedeven when the cutting operation is performed with a relatively high feedamount. In addition, since a considerably large effective rake angleexists, burrs or the like are less produced and an intermittent cuttingoperation can be effectively done.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a perspective view showing one example of an oblique edgedtool of a prior art;

FIG. 2 shows an end view of the tool shown in FIG. 1;

FIG. 3 is a perspective view showing a cutting operation condition inuse of the oblique edged tool shown in FIG. 1;

FIG. 4 is a perspective view showing another example of an oblique edgedtool of a prior art;

FIGS. 5 and 6 are also perspective views showing work cutting operationconditions in use of a cutting tool provided with a cutting tip of aprior art, respectively;

FIG. 7 is a perspective view showing a tip used for the cutting toolshown in FIG. 4 for showing a wear condition of the tip;

FIGS. 8A through 8C are schematic representations for explaining therelationship between a work to be machined and a cutting edge of anoblique cutting tool;

FIG. 9 is a view for showing the maximum height of the surface roughnessof the machined work;

FIG. 10 is a perspective view showing a tip illustrated for explainingthe length of the cutting edge of the tip;

FIG. 11 is a perspective view showing an embodiment of an oblique edgedtool according to this invention;

FIG. 12 shows an end view of the tool shown in FIG. 11;

FIGS. 13 through 16 are perspective views showing other embodiments ormodifications of the oblique edged tools according to this invention,respectively;

FIGS. 17 through 19 are representations for explaining a gap betweentips when the tips are disposed as shown in FIG. 16;

FIG. 20 is a front view showing a further embodiment of an oblique edgedtool according to this invention;

FIG. 21 is a perspective view showing the oblique edged tool shown inFIG. 20;

FIGS. 22A and 22B are plan and front views of the tip attached to thetool shown in FIG. 20 or 21;

FIG. 23 is a perspective view showing the work cutting condition in useof the oblique edged tool shown in FIG. 20 or 21;

FIG. 24 is a view for explaining the tip under the cutting conditionprojected on the three dimensional planes;

FIG. 25 shows a graph representing surface roughness in an enlargedscale of a machined work;

FIG. 26 shows a shape of a part of a chip produced by the cuttingoperation;

FIG. 27 is a perspective view showing the tip in the cutting operationwith the chip produced;

FIG. 28 is a modeled perspective view for explaining relationshipsbetween various angles and cutting directions of the cutting tip and thechip in the cutting operation;

FIG. 29 is an enlarged schematic view of the part of the chip forexplaining the flow-out angle of the chip;

FIG. 30 is a view of the cutting tip for explaining the cutting velocitydirection of the work and feeding direction of the tool;

FIG. 31 is a perspective view of the cutting tool which cuts the outerperipheral surface of a cylindrical work;

FIG. 32 is also a perspective view of the cutting tool which cuts theinner peripheral surface of a ringshaped work;

FIGS. 33A and 33B are plan and front views of an equilateral square tipused for the oblique edged tool according to this invention;

FIG. 34 is a front view showing the oblique edged tool in which theequilateral square tip shown in FIG. 33 is vertically attached;

FIG. 35 is a perspective view showing the oblique edged tool shown inFIG. 34;

FIG. 36 is a perspective view of another example in which theequilateral square tip is attached by the manner different from thatshown in FIG. 35;

FIG. 37 is a front view of the tool shown in FIG. 36;

FIG. 38 is a perspective view of further example of the attachment ofthe equilateral square tip similar to that shown in FIG. 36;

FIG. 39 is a schematic partial view showing a condition in which a workis cut by the oblique edged cutting tool of this invention;

FIGS. 40A and 40B are plan and front views of a ring-shaped tip to beused for the oblique edged tool according to this invention;

FIG. 41 is a front view of a front end of the tool provided with thering-shaped tip shown in FIG. 40;

FIG. 42 is a perspective view of the oblique edged tool shown in FIG.41;

FIGS. 43 and 44 show further modifications of the oblique edged toolprovided with the triangular tips;

FIG. 45 is a perspective view of the further modification of the obliqueedged tool provided with a curved triangular tip according to thisinvention;

FIG. 46 is a perspective view showing a cutting condition of a work inuse of the tool shown in FIG. 45;

FIG. 47 is a schematic illustration for showing the inclined conditionof the tip provided with the curved cutting edge;

FIG. 48 shows a cutting tip inclined by a certain normal rake angle ofα_(n) in the cutting operation;

FIG. 49 is a graph for showing curves representing the maximum surfaceroughness of a machined work;

FIG. 50 shows a certain example of the surface roughness of the machinedwork obtained by using the cutting tool of this invention;

FIG. 51 is a graph showing the actual or theoretical surface roughnesscondition of the machined work in connection with the feed amount of thecutting tool of this invention;

FIG. 52 is a perspective view of the curved cutting edged tip in anactual cutting operation;

FIG. 53 is a partial perspective view of a chip;

FIG. 54 is a view similar to FIG. 30 for explaining the cutting verocitydirections in connection with the cutting angles during the cuttingoperation;

FIG. 55 is a view for explaining the relationship between the cuttingdirection and the feeding direction of the tip based on the cuttingoperation for this invention;

FIG. 56 is a perspective view showing work cutting condition of acylindrical work;

FIG. 57 is a schematic view, similar to FIG. 47, showing a relationshipbetween the inclination of the tip edge of the cutting operation shownin FIG. 56;

FIG. 58 is a perspective view of a modified example of the oblique edgedtool in which a substantially square tip is attached;

FIGS. 59 and 60 show cutting conditions of the tool shown in FIG. 58 inwhich the inner surface of the cylindrical or ring-shaped work is cut;

FIG. 61 is a partial perspective view of a further modified embodimentof the oblique edged tool in which a hexagonal tip is attached accordingto this invention;

FIGS. 62 and 63 are perspective views of tips having substantially thetraingular outer configurations in a plan view which are adapted for acutting tool according to this invention;

FIG. 64 is a perspective view of a cutting tool of this invention towhich the tip shown in FIG. 63 is attached so that the curved cuttingedge projects outwardly;

FIGS. 65 and 66 are perspective views of tips having substantially thesquare outer configurations in a plan view which ar adapted to a cuttingtool according to this invention;

FIG. 67 is a perspective view of a cutting tool of this invention towhich the tip shown in FIG. 66 is attached in a manner similar to thatof FIG. 64; and

FIGS. 68 through 75 are also perspective views of tips of other typeswhich are however attached to the cutting tool of this invention in themanner similar to that of FIG. 64 or 67.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Ahead of the disclosure of embodiments of this invention, will first bedescribed the length of the cutting edge of an oblique edged toolcontacting to a work with reference to FIG. 7.

FIG. 7 shows a worn condition of the specifically made tip 6 attached tothe oblique edged tool 5 shown in FIG. 4, and as is apparent from FIG.7, when the tip 6 is set to the tool 5 in a manner that the intermediatepoint P of the oblique cutting edge 7 is located on the same level asthe central axis of the work and cutting operation is carried out, it isobserved that the cutting edge 7 is worn at the portion lower than thepoint P and almost not worn at the portion above the point P as viewedin FIG. 7. This fact will be deemed to require the reconsideration onthe point that the specifically made tip having a cutting edge longerthan that of the conventional indexable throw-away type standard tip hasto be used for the oblique edged tool. Hereinafter, the term of"standard tip" means an indexable throw-away type standard tip which hasan outer configuration radially symmetrical about its geometric center.

Next, consideration on the length of the cutting edge of the obliqueedged tool contacting the work will be made geometrically hereunder inconjunction with FIGS. 8A through 8C and FIG. 9.

FIGS. 8A through 8C show the positional relationship between the cuttingedge 7 of the oblique edged tool 1 and the work 4 to be machined, and inFIG. 8B, the cutting edge 7 inclined by an angle α with respect to theaxis O-O' of the work 4 starts to contact the work 4 at the cuttingstart point A and the work 4 is finished to have a machined radius Rwhen the cutting edge reaches the point P located on the level of theaxis O-O' of the work 4. However, after passing the point P it will beobserved that the machined surface of the work 4 provides wave shapedsurface roughness. FIG. 9 shows the maximum height H of this surfaceroughness and the height H appears at the point B apart from the point Pby a distance half (f/2) of the feeding amount f per one rotation of thework 4.

The maximum height H will be obtained by the following manner inconsideration of the right-angled triangle O'B'P' formed as shown inFIG. 8C, in which O'P'=R, P'B'=f/2 tanα and <O'P'B'=90°. Then thefollowing equation is established. ##EQU1## From the equation (1), itwill be found that the roughness of the machined surface of the work isdegraded as the feed amount f increases or the inclination α becomeslarge, whereas the surface roughness is improved as the radius R of thework 4 increases.

The length of the cutting edge 7 of the oblique edged tool contactingthe work 4 will be considered hereunder.

Generally, in a case where a chip is continuously produced in a cuttingoperation of a circular work 4, it is observed that a thin chip havingrelatively wide width portions and relatively narrow width portions isflown out with twisted condition and fallen down along the obliquesurface of the tip. The chip having relatively wide width portions isproduced when the work is cut by the cutting edge l_(A) below the pointP of the cutting edge 7 as viewed in FIG. 8B and the chip havingrelatively narrow width portions is produced when the work is cut by thecutting edge l_(B) above the point P.

The length l_(A) of the cutting edge will be expressed as follows asshown in FIGS. 8B and 8C, in which depth of cut in the radial directionof the work 4 is designated by t, ##EQU2## While, the length l_(B) ofthe cutting edge will be expressed as follows as shown in FIGS. 8B and9, ##EQU3##

In an actual numerical example, for example, in which a circular workhaving diameter of 100 mm at feeding speed f of 0.5 mm/rev. by using anoblique edged tool inclined by angle α of 60° to obtain depth of cut of0.1 mm, ##EQU4## It will be understood from this example that the lengthl_(B) of the cutting edge above the point P is merely 0.5 mm, being 1/7of the length l_(A) and the entire length l=(l_(A) +l_(B)) of thecutting edge is 4.151 mm, which shows the fact that a standard squaretip having one side of 4.762 mm or a standard triangular tip havingradius of an inscribed circle of 3.969 mm can effectively be utilized asa cutting tip for an oblique edged tool for this invention.

The following table shows the maximum diameters of works which can bemachined by standard tips having various sides and the maximum allowablecut depths when a work having diameter of 100 mm is cut by the varioussized standard tips of the indexable throw-away type.

                                      TABLE 1                                     __________________________________________________________________________    Unit (mm)                                                                                        Maximum Diameter of Work to                                Shape of                                                                             Length of One Edge of                                                                     Be Machined with Feed                                                                         Allowable Depth of Cut                     Standard Tip                                                                         Standard Tip (Radius of                                                                   Amount of 0.5 mm/rev. and                                                                     When Work with                             (ISO)  Inscribed Circle)                                                                         Depth of Cut of 0.2 mm                                                                        Diameter of 100 mm Is                      __________________________________________________________________________                                       Cut                                        Equilateral                                                                           6.875 (3.969)                                                                            152.402         0.305                                      Triangular                                                                           8.248 (4.762)                                                                             225.118         0.450                                      Tip    9.623 (5.556)                                                                             312.109         0.624                                             10.999 (6.350)                                                                            413.359         0.827                                             13.749 (7.938)                                                                            658.260         1.317                                             16.498 (9.525)                                                                            959.760         1.920                                             21.997 (12.700)                                                                           1,653.120       3.466                                             27.496 (15.875)                                                                           2,732.940       5.466                                             32.966 (19.050)                                                                           3.959.963       7.920                                      Equilateral                                                                          3.969        45.127         0.090                                      Square 4.762        68.117         0.136                                      Tip    5.556        95.862         0.192                                             6.350       128.334         0.257                                             7.938       207.464         0.415                                             9.525       305.440         0.611                                             12.700      558.150         1.116                                             19.050      1,290.384       2.581                                             25.400      2,325.038       4.650                                      __________________________________________________________________________     Note 1: The length l of one edge of the tip is a value when it is suppose     that the radius of the nose of the tip is zero.                                Note 2: The maximum diameter of the work is obtained on the basis of 3.7     (l - 0.5).sup.2.                                                              Note 3: The allowable depth of cut is obtained on the basis of 0.0075 (l      0.5).sup.2.                                                              

It will also be understood from the foregoing description that thevertical intermediate point of the cutting edge of the inclined tip doesnot accord with the level of a plane including the axis of the work, andotherwise, a point P near the upper end of the cutting edge is locatedso as to accord with the level of the axis of the work and to have alength of approximately l_(B) or slightly more between the point P andthe upper end of the cutting edge 7 of the tip 6 as shown in FIG. 10,whereby a tip having a cutting edge length of about half of that of theconventional specifically made tip can be availably utilized.

FIG. 11 and 12 represent one embodiment according to this invention, inwhich a triangular tip 12 of an indexable throw-away type standard tipis fitted to the front end of a holder or shank 3 of rectangular cubicshape of an oblique edged tool 11. The front end of the holder 3 doesnot exist in a plane shown by broken lines in FIG. 11, and actually, thefront end 13 thereof is inclined as shown by solid lines towards thetangential direction from a tip mount position 14 of the holder 3 sothat the flank surface of the tip 12 does not contact the work to bemachined. The relief angle of the surface 13 is predetermined to beapproximately 10°. Accordingly, as shown in FIG. 11, the relief anglesε, ε' are provided for the respective sides of the holder 3. The tipmount portion 14 is formed between the inclined front surface 13 and arear surface 15 parallel thereto at the corner portion of the holder 3.On a flat and horizontal base 16 of the tip mount portion 14 is locateda shim 17 made of super hard alloy or hardened steel. The upper surface18 of the shim 17 and the oblique surface 19 of the tip mount portion 14are respectively normal to the rear surface 15. The tip mount portion 14thus defined by these surfaces can significantly accord with the outerconfiguration of the triangular tip 12 to be used.

A swingable pin 20 is projected from the rear surface 15 of the tipmount portion 14 for supporting the tip 12 and the pin 20 is swung indirections apart from or approaching a bolt 21 fixed to the front endsurface 13 of the holder 3 by rotating the bolt 21.

When it is required to mount the standard triangular tip 12 on the tipmount portion 14, the tip 12 is first positioned on the tip mountportion 14 so that the central hole 22 of the triangular tip 12 isfitted by the pin 20 and the bolt 21 is rotated so that the front end ofthe pin 20 is inclined towards the bolt 21 thereby to press the tip 12against the oblique surface 19 of the tip mount portion 14 and the shim17.

Although the inclination angle α of the cutting edge of the tip 12 isgenerally selected from the range of 30° ˜70° with respect to thehorizontal surface, it was found in our experiment that the cuttingoperation of the cutting edge of the tip 12 with the inclination ofapproximately 60° can be availably performed in view of the cuttingresistance, vibrations or the like. Accordingly, since the triangulartip 12 is positioned as shown in FIGS. 11 and 12 and has the equilateralshape, the inclination α of the cutting edge 23, in FIG. 12, is 60°,thus being available.

In addition, since the relief angle is provided at the front end of theholder 3 and the shim 17, the pin 20 and the bolt 21 are located so thatthe front ends thereof are not projected beyond the front surface 13 ofthe holder 3, only the cutting edge 23 of the triangular tip 12 contactsthe work surface. Moreover, the tip 12 can positively be supported bythe pin 20, and the main component of the cutting resisting force actingon the cutting edge 23 during the cutting operation acts downwardly, butthe tip 12 can be safely maintained by the existence of the shim 17having relatively large strength between the base of the tip mountportion 14 and the lower surface of the tip 12. Furthermore, since thetriangular tip 12 has an outer configuration radially symmetrical aboutits geometric center and is provided with six long edges having the samelength, these edges can be used alternately as a cutting edge when oneof these edges has been worn.

In one example, when the triangular tip 12 having a radius of theinscribed circle of 12.7 mm which is widely used in this industrialfield is used, one side length of the triangular tip 12 is approximately22 mm in no consideration of slightly round noses, and supposing thatthe cutting operation is performed at the feed amount f of 0.5 mm/rev.with a triangular tip having an inclination of 60° to obtain a depth ofcut t of 0.2 mm, a work having a diameter of approximately 1653 mm canbe cut by the calculation in accordance with the equation (2) andequation (3). Since the use of a work having a diameter more than 1653mm is very rare case, this standard triangular tip widely used can beavailably utilized for almost all cutting operation.

In addition, in a conventional cutting operation, the corner portions ofthe tip wear, but with the tip of the embodiment of this invention, thelongitudinal intermediate edge portion can be utilized for the cuttingoperation, so that the tip once used for the conventional tool can bereused, or reversely, the tip once used for the oblique edged tool ofthis invention can also be reused for the conventional cutting tool inwhich the nose portion of the tip is utilized for cutting the work.

FIG. 13 shows another embodiment of the use of the tip in which thetriangular tip 12 used for the example shown in FIG. 11 or 12 ispositioned on the tip mount portion 14 in a positional relationshipdifferent from that shown in FIG. 11. Referring to FIG. 13, the tipmount portion 14 is formed at the front end portion of the inclinedsurface 24 formed at the front end of the holder 3. The surface 24 isinclined by an angle of 60° with respect to the horizontal surface andthe side surfaces 25 of the tip mount portion 14 intersect with eachother with an angle of 60° therebetween. The shim 17 is located on thebase surface 26 of the tip mount portion 14, from which the pin 20projects to be swingable by the bolt 21 as described in connection withthe example shown in FIG. 12. The cutting edge 23 of the tip 12 isaligned with the front surface 13 of the holder 3.

According to the arrangement of the tip 12 described above, a breaker 27having a positive rake angle serves effectively for the cuttingoperation and improves the cut condition thereby to reduce the cuttingresistance as well as the production of burrs.

FIG. 14 shows a perspective view of another example according to thisinvention, in which a standard equilateral square tip 28 is fitted tothe holder 3 in the vertical state by the manner substantially identicalto that shown in FIG. 11. The equilateral square tip 28 is provided witheight cutting edges 23, more edges thus being available in comparisonwith the equilateral triangular tip.

FIG. 15 shows a perspective view in which the equilateral square tip 28is located by the manner substantially identical to that mentioned inconnection with the equilateral triangular tip as shown in FIG. 13, andin this example, the braker of the tip 28 serves effectively for thecutting operation.

FIG. 16 shows one modification of the example shown in FIG. 15, in whichtwo pins 20A and 20B located with space on the tip mount portion so asto project obliquely upwardly therefrom and the bolts 21A and 21B arealso located to the inclined surface 24 on positions corresponding tothe pins 20A and 20B, respectively. In an actual attachment of theequilateral square tips 28, 28, two tips are fitted side by side so thatthe pins 20A and 20B are fitted into the central holes 22, 22 of thetips 28, 28 and the cutting edges of both tips are aligned thereby toprovide a relatively long cutting edge to cut the work having a largediameter.

With the embodiment shown in FIG. 16, a gap having a width of 2r may beformed because the tip 28 has a round nose portion having a radius r atthe corner portion thereof, so that when the work is machined by thistype cutting tool, non-machined portions are linearly formed on thesurface of the work. Each of the non-machined lines has a width 2r whenthe tips are not inclined as shown in FIG. 18, whereas the line has awidth r when the tips are inclined by an angle of 60°, for example shownin FIG. 19. It may be of course possible to arrange three of moreequilateral triangular or square tips in the oblique manner as occasiondemands.

According to this invention, the oblique edged cutting tool providedwith a tip of an indexable throwaway type has an outer configurationradially symmetrical about its geometric center, so that the cuttingedges are increased without a specifically manufactured tip, andmoreover, standard tips such as made in accordance with ISO can beutilized.

In the foregoing description, reference is made to an oblique edgedcutting tool provided with a standard tip having straight cutting edgesand being of an indexable throw-away type, but this invention is notlimited to the standard tip of this type and the other tips each havingan outer configuration radially symmetrical about its geometric centercan be applied.

Moreover, as described in detail hereinafter, there can be used, for theoblique edged cutting tool, a tip having curved cutting edges and havinga substantially equilateral or circular outer configuration radiallysymmetrical about its geometric center.

FIGS. 20 through 22 show a tip 102 having an outer configuration ofsubstantially equilateral triangular shape and an oblique edged cuttingtool to which the tip of this shape is attached. As shown in FIGS. 22Aand 22B, the tip 102 has slightly curved cutting edges 106 and athickness t, and the cutting edge 106 is shown by an arc of a circlehaving a radius R. An attachment hole 107 is provided for the centralportion of the tip 102.

As shown in FIGS. 20 and 21, the tip 102 is fitted in a notch recess 108and a shim 109 is interposed between the tip 102 and the bottom 108a ofthe notch recess 108. An escape hole 110 is formed at the boundaryportion between the bottom and side surfaces 108a and 108b of the recess108. The tip 102 is secured to or removed from the shank or holder 101of the tool by rotating a clamp bolt 111 to permit a pin or lever 112inserted into an attachment hole 107 to take a locking or unlockingposition, and under the secured condition only the cutting edge portion106a located most outside of the cutting edge 106 of the tip is utilizedfor cutting the work.

An inclination i of a tangential line m at substantially intermediatepoint P_(o) of the cutting edge portion 106a is an angel defined by thetangential line m and a line l normal to the cutting direction V_(w), asshown in FIG. 24, and the angle i is usually set to a value between 30°and 70°. In the embodiment illustrated in FIG. 20, since substantiallythe equilateral triangular tip 102 is used at the vertically securedstate, the angle i is set to 60°, and as is apparent from FIG. 21, a tiptake-out pocket 113 is formed at a portion of the shank 101 behind thecutting edge 106a.

The cutting edge 106a is provided with an end relief angle ε (FIG. 11)and as shown in FIG. 20 or 21, when the end relief angle ε is set alonga perpendicular line n normal to the tangential line m passing theintermediate point P_(o) of the cutting edge 106a having a radius R ofcurvature, the point P_(o) projects towards the most forward portion ofthe shank 101 thereby to have a large depth of cut. The angle ε is oftenset to a value within the range of 3°˜11°. The break lines written infront of the shank end shown in FIG. 21 show an imaged surface normal tothe longitudinal axial line fo the shank 101 and as is apparent fromthis imaged surface, the actual front end surface of the shank 101 issomewhat inclined because of the existence of the end relief angle ε.

FIG. 23 is a perspective view of one example of the cutting condition ofthe cutting tool according to this invention in which the end surface114 of a circular work 103 is subjected to the cutting operation by amachine tool such as a vertical lathe. In this example, the shank 101 ispositioned so that the longitudinal axis of the shank 101 issubstantially normal to the end surface 114 of the work 103 and thepoint P_(o) and portions near the point P_(o) of the curved cutting edge106a of the tip 102 are entered into the work 103.

FIG. 24 shows a projected condition of the cutting edge 106a of the tip102 in the cutting operation into three planes P_(xy), P_(xz) andP_(yz), respectively normal to each other in a cubic space.

In FIG. 24, since the cutting edge 106a of the tip 102 is approximatelyparallel to the cutting surface, but with the end relief angle ε,parallel to the plane P_(xy), the actual cutting edge portion 106a ofthe cutting edge 106 performs a cutting operation with a large curvedcutting edge, so that the maximum value Ho of the roughness of themachined surface of the work is extremely small and the surface thusmachined is substantially plane even if the feed amount of the tip islarge.

FIG. 25 shows a curve representing the roughness of the machined surfaceof the work which is cut in accordance with cutting conditions shown inthe following Table 2 by using a cutting tool according to thisinvention.

                  TABLE 2                                                         ______________________________________                                        Items           Cutting Conditions                                            ______________________________________                                        Substance of work to be                                                                       Stainless steel (13 chromium, 4.5                             machined        nickel alloy)                                                 Machine tool    Extension boring and turning mill                             Cutting speed   120 m/min.                                                    Feed amount     5.2 mm/rev.                                                   Cutting depth   0.03 mm                                                       cutting condition                                                                             Intermittent cutting                                          ______________________________________                                    

As is apparent from the measured result shown in FIG. 25, it was foundthat an approximately maximum roughness 3.2 μm of the machined surfacecould be obtained with the feed amount 5.2 mm/rev. in the intermittentcutting operation of a stainless steel work.

In FIG. 24, when it is supposed that the cutting edge 106a is projectedon the plane P _(xy), the inclination between the tangential line m atthe point P_(o) which is substantially the intermediate portion of bothends A and B of the cutting edge 106a and a line l normal to the cuttingdirection V_(w) forms an angle i, and a shpae of the cutting edge 106aprojected on the plane P_(xy) exhibits a mount shape facing the cuttingdirection V_(w) with the center being the intermediate point P_(o) ofthe cutting edge 106a.

As shown in FIG. 23, in a case where the cutting tool is fed in the toolfeeding direction f normal to the cutting direction V_(w), the cuttingedge 106a has a projected mount-shape with the center being theintermediate point P_(o) with respect to the feeding direction f.

A projected image of the cutting edge 106a on the plane P_(xz) exhibitsa mount-shape curved line with respect to an entering direction(downward direction as viewed in the drawing) and the projected image onthe plane P_(yz) also exhibits a mount-shape curved line with respect tothe entering direction. The fact that the cutting edge 106a providedwith the inclination angle i acts as the cutting edge having mount-shapecurved lines in the respective directions means that the strength of thecutting edge can be improved in comparison with a case where the cuttingedge acts as a cutting edge having a straight line and that the cuttingedge is gradually contacted with the work thereby to gradually increasethe cutting amount and to gradually decrease the cutting amount afterthe cutting amount becomes maximum, whereby a fine machined surface isexhibited. It will also be found that the cut chip has a cross sectionhaving thin thickness at both ends thereof.

In consideration of a cutting temperature of the work due to the colorchange of the chip of a soft steel, it will be found that both ends Cand D of the chip exhibit a pale silver-white color representing arelatively low cutting temperature and the central portion thereofexhibits a dark blue color representing a relatively high temperature.The fact that the temperature of one end of the chip in contact with themachined suface of the work 103 is relatively low means that themachined surface is less affected by the thermal deformation or thermaldamage.

FIG. 27 shows a perspective view in an enlarged scale of the tip 102 inthe cutting operation, in which the cutting edge 106a having a largeradius of curvature R has an attitude in which the flat surface of thetip 102 is fallen to a position approximately parallel to the cuttingsurface 115 with the relief angle ε, so that the cutting edge 106a canperform a cutting operation with a large radius of curvature, wherebythe maximum value H_(o) of the roughness of the machined surface of thework becomes extremely small even if the feed amount f is increased. Acut section s of a portion to be cut and a projected image s' of thatportion on the X-Z plane have shapes respectively shown in FIG. 27 andthe cross sectional shape of the chip 116 has a central portion havingrelatively thick thickness and end portions having relatively thinthickness as shown in FIG. 26. This fact means that the curved cuttingedge 106a gradually enters in the work 103 to produce the machinedsurface gradually. The surface of the work advancing towards the curvedcutting edge 106a at the cutting speed V_(w) is cut by the cutting edge106a and the chip 116 is flown out at a speed V_(c). The chip 116 isflown out in a direction which is a function of the inclination i of thecutting edge 106a. The chip flow-out angle is designated ηc hereinbelow.The chip 116 is as a whole flown out in an inclined direction of thecutting edge 106a with a twisted condition.

FIG. 28 shows a view for explaining relationships between respectiveangles and speeds of the chip 116 and the curved cutting edge 106a, andin FIG. 28, the feed amount f shown in FIG. 23 or 27 is eliminated forthe clarification of the explanation and the width of the work isnarrowed less than the width of the cutting edge 106a. In addition, thechip 116 is linearly flown out without twisting for clearly showing thechip flow-out direction. In FIG. 28, a symbol V_(w) designates a cutspeed of the work 103, V_(c) is a flow-out speed of the chip 116, α_(n)is a normal rake angle, α_(e) is an effective rake angle, and η_(c) is achip flow-out angle.

In general, when the cutting edge 106a is inclined by an angle i withrespect to the direction normal to the cutting direction, the chipflow-out angle ηc is an angle constituted by a plane normal to thecutting edge 106a and the chip flow-out direction and measured on therake surface of the chip 116, and the following equation is establishedfrom a geometrical view point.

    sinα.sub.e =sinηc·sini+conηc·cosi·sinα.sub.n (4)

In the equation (4), the normal rake angle α_(n) is a rake angle in aplane normal to the cutting edge and the machined surface of the workand is set at the designing time of the cutting tool, and accordingly,the normal rake angle α_(n) is easily measured. The effective rake angleα_(e) is a rake angle in a plane including the cut speed v_(w) and thechip flow-out speed V_(c) and is the most important rake angle for acutting mechanism. With the equation (4), it will be found that theeffective rake angle α_(e) can be calculated when the chip flow-outangle η_(c) is obtained. The angle ηc will be obtained as an approximatevalue by applying measured values of the width b of the work 103 beingequal to the width of the cut width and the width b_(c) of the chip 116into the following equation (5).

    cosηc=b.sub.c cosi/b                                   (5)

In an actual measurement of the chip width, the cut width and the normalrake angle and calculation of the chip flow-out angle, it was found thatwhen the inclination i at the point P_(o) of the cutting edge 106a is60° and the normal rake angle α_(n) is -10°, the chip flow-out angle ηcis about 50° and the effective rake angle α_(e) representing a cuttingperformance or cut condition is about 40°. This result means that evenif the cutting tool is itself not provided with a sufficient large rakeangle, a cutting operation can be performed with a high cuttingperformance by inclining the cutting edge.

Although FIG. 28 is utilized for explaining the cutting mechanism orprinciple on the point P of the inclined cutting edge 106a, FIG. 29shows a perspective view of a part of the chip 116 for explaining chipflowout angles ηc₀, ηc₁, ηc₂, ηc₃ and ηc₄ on points P₀, P₁, P₂, P₃ andP₄ of the cutting edge 106a, respectively, and it will be found that theflow-out angles on the respective points are significantly differentfrom each other on the basis of the difference between the inclinedangle represented by the inclination of the tangential line and the rakeangle at each point. For the reason mentioned above, a strain inside thechip 116 is dispersed to likely expand the width thereof, and theconfiguration of the cutting edge is transferred to the chip, so thatthe cross section of the chip is curved and strengthened. Accordingly,since the chip is smoothly flown out as a whole in the incliningdirection of the cutting edge 106a, the chip 116 is not twined round thecutting edge 106a or does not adhere thereto, thus significantlyrestricting wear of a tool resulting from the chip adhesion to thecutting edge and improving the durability of the tool in comparison withcutting tools of conventional type.

FIG. 3 is a view for explaining the relationship between the cuttingdirection and the feeding direction of the tip 102 on the point Po ofthe cutting edge 106a thereof, and in this figure, only the projectedcutting edge 106a is shown by a solid line. In FIG. 30, in a case wherethe cutting direction is represented by the arrow V_(w1), the feedingdirection will be chosen to the direction f₁ or f'₁, while representedby the arrow V_(w2), the feeding direction will be chosen to thedirection f₂ or f'₂, thus being convenient for the practical use of thecutting tool.

The main component of cutting resisting force acting on the cutting edge106a acts in the same direction as the cutting direction, so that theacting direction of the main component of force F_(p) when the cuttingdirection is V_(w1) substantially accords with the direction f'₂.

With a conventional cutting tool, since the main component of thecutting resisting force is applied to a thin thickness portion of a flattip 102 as shown in FIG. 5 or 6, the tip 102 is liable to be damaged,but according to the cutting tool of this invention, the main componentof force F_(p) is applied in a large sized direction of the flat tip 102as shown in FIG. 30, so that the strength of the tip increases.

According to the embodiment of this invention described above, in whicha flat tip provided with a peripheral curved cutting edge having aradius of large curvature is inclined to a position substantiallyparallel to the surface of a work to be machined with only a reliefangle ε therebetween and the cutting edge of the tip is also inclinedwith respect to the cutting and feeding direction, such advantages oreffects as summarized as follows will be expected.

(1) Since the cutting edge utilized directly for the cutting operationis constructed as a curved cutting edge having a radius of largecurvature with respect to the cutting edge entrance direction, a goodcut surface roughness can be obtained even when the cutting edge is fedat a relatively large feeding speed.

(2) Since the cutting edge performs the cutting operation as a cuttingedge having a radius of large curvature and inclined with respect to thecutting and feeding directions, there are obtained a relatively largeeffective rake angle and an improved cutting performance, and inaddition, burrs or the like are less formed and extremely fine enteringoperation can be performed. Moreover, the work is gradually cut, so thatthe cutting impact is not applied at one time thereby to prevent thecutting edge from damaging as well as to effectively suppressundesirable chatter vibrations.

(3) Since a cut chip has a curved cut cross section, the chip issmoothly flow out as a whole in an inclined direction of the cuttingedge, whereby the cut chip does not adhere to the cutting edge therebyto improve the durability against wear of the cutting edge.

(4) Since the cutting and feeding directions can optionally be selectedwith the attitude of the cutting edge maintained, the cutting operationcan be performed with high efficiency. In addition, the cuttingdirection is variable in a range of angles of from 0° to 90° and anopposing feeding direction can be selected as the feeding direction.

(5) Since the curved cutting edge portion of the tip can be utilized forthe actual cutting portion, the tip can be reused after the curvedcutting edge has been worn as a conventional tip which utilizes thecorner edge portions thereof as cutting edges, thus being economical. Inaddition, since the tip of this invention has a radius of considerablylarge curvature, the tip can be attached with no problem to a cuttingtool of conventional type.

(6) The cutting tool of this invention can be utilized for an outerperipheral surface machining (FIG. 31) and an inner peripheral surfacemachining (FIG. 32) as well as an end surface machining (FIG. 23).

(7) Since the tip according to this invention can be attached to thecutting tool so as to exhibit its most large size with respect to thedirection of the main component of the cutting resisting forcecorresponding to the cutting direction, the strength of the cutting edgeis improved and the durability thereof can be expanded, as well as theapplication to the intermittent cutting operation or difficult cuttingoperations of hard materials with large impacts or vibrations. Inaddition, because of the cutting edge being curved in variousdirections, the strength thereof is improved in comparison with thestraight cutting edge thereby reducing wear and damage.

FIGS. 33 through 44 show the other embodiments according to thisinvention, in which like reference numerals are added to elements orparts corresponding to those shown in FIGS. 5 and 6 and FIGS. 20 through32.

FIGS. 33A and 33B show respectively a plan and side views of asubstantially equilateral square tip 102 having four sides as cuttingedges 106 each outwardly protruding in mount shape.

FIG. 34 shows a front view in which the square tip 102 is detachablyfitted to the front end of the shank 101 of a cutting tool with astanding condition having one corner directed downwardly. In thisembodiment, although the inclination i is defined to 45°, it is notnecessary to limit this angle as described with respect to the foregoingembodiment.

FIG. 35 is a partial perspective view of the embodiment shown in FIG.34, in which the tip 102 is fitted in the recessed portion of the frontend of the shank 101.

FIG. 36 shows another embodiment similar to that shown in FIG. 33, inwhich the tip mounting portion 117 of the shank 101 is constructed to bewidely opened for facilitating the tip attachment.

FIG. 37 shows a front view showing the tip attaching condition similarto that shown in FIG. 34, but in FIG. 37, upper two cutting edges 106aand 106a' are adapted so as to provide a relief angle towards thecentral line h of the tip 102 and the shank 101.

FIG. 38 shows a partial perspective view of the example shown in FIG.37.

FIG. 39 is a partial plan view showing the cutting tool shown in FIG. 38in connection with the work 103, in which the shank 101 is tapered withan angle γ in the width direction of the shank 101, and accordingly,when one side of the shank 101 is pressed to one side surface 118a of acutter holder 118, a front cutting edge angle of γ is also provided forthe tip 102 attached to the front end of the shank 101 and the actualcutting edge portion 106a projects forward of the shank 101. On thecontrary, when the cutting edge 106a' is utilized for the cuttingoperation, the other side of the shank 101 may be pressed to the otherside of the cutter holder 118. In addition, in the usual operation whenthe feeding direction f is reversed, the inclination i becomes -i as anapparent angle, but according to this invention, such a change of theapparent angle is not observed, and there is no change of the flowingmode or shape of the chip.

FIGS. 40A and 40B show front and side views of a circular tip 102according to another example of this invention, in which the circulartip 102 is provided with a cutting edge 106a along the whole peripheralsurface thereof.

FIG. 41 shows a front view in which the circular tip 102 shown in FIG.40 is detachably fitted by a lever 112 to the recessed portion of thefront end of the shank 101 with the standing state. With the circulartip 102 shown in FIG. 41, the point P_(o) and portion near that point ofthe cutting edge of the tip 102 is utilized for the actual cuttingoperation, and accordingly, the tip 102 is attached to the shank 101 sothat the point P_(o) projects forwardly of the holder and relief anglesε are provided for the front portion of the shank 101 and the tipmounting portion 117.

FIG. 42 shows a partial perspective view of the embodiment shown in FIG.41, in which the shim 109 is interposed between the back surface of thetip 102 and the recessed front end of the shank 101. With the embodimentof the circular tip 102 illustrated in FIG. 42, the whole peripheralcutting edge 106a is utilized for the cutting operation subsequently byrotating the same in consideration of the worn degree of the point P_(o)of the cutting edge 106a, thus being economical. In addition, since thecircular tip is not provided with a cutting corner edge, a cutting depthis set to be relatively large thereby to facilitate wide use thereof,particularly for the machining of the inner peripheral surface of awork.

The shim 109 is usually interposed between the tip 102 made of asintered carbide material and the shank 101 made of a material havingrelatively low hardness for preventing the shank 101 from damaging, butthe location of the shim 109 is not essential for this invention whichwill be understood by those skilled in the art.

In the embodiments disclosed hereinbefore, although wall portions 117aof the tip mounting portion 117 of the shank 101 are formed so as tohave curved shapes corresponding to the outer configuration of the tipto be used, the wall portions may be constructed to be straight walls asshown in FIG. 43 or to have escape grooves 119 at two edge points q ofwhich the cutting edges 106 of the tip 102 contact to support the tip102 as shown in FIG. 44. Of course, the alternations described abovemayh be applied to the shank 101 for the square tip and the circulartip. Moreover, although in the foregoing embodiments, the rotating speedis endowed by rotating the work, it is of course possible to rotate orlinearly move the cutting tool. In addition positive tips can beutilized instead of negative tips.

Finally, this invention will be summarized as follows for the aid of theeasy understanding of this invention. Namely, this invention relates toan oblique edged cutting tool provided with a front end portion to whichis attached a tip of an indexable throw-away type having an outerconfiguration radially symmetrical about its geometric center, and thetip is provided with a plurality of straight or curved cutting edgeshaving substantially the same length, respectively. Furthermore, theattachment of the tip can be performed in the manner that the tip isattached to the front end of the cutting tool so as to be substantiallyparallel or normal to the work surface to be machined.

Further, modified embodiment of this invention will be describedhereinafter in conjunction with FIGS. 45 through 61, in which asubstantially equilateral tip or circular tip provided with a curvedcutting edge having a radius of large curvature, the tips beingsubstantially the same type as those referred to in connection withFIGS. 20 through 44, is attached to the front end of the oblique edgedcutting tool so as to be vertical to the surface of a work to bemachined under the operating condition.

FIG. 45 shows a perspective view of a further modified example accordingto this invention, in which a substantially triangular tip 203 providedwith a curved cutting edge 202 and having considerably large radius ofcurvature is made of a hardened material and detachably fitted to a tipmount portion 206 formed obliquely at the inclined end surface portionof a holder 204 of a cutting tool 201. The inclination i of the tip 203,i.e. the cutting edge 202 thereof, is preferably defined toapproximately 30°˜70°.

FIG. 46 is a perspective view showing a cutting operation condition of aflat surface 208 of a ring-shaped work 207 in use of a vertical boringand turning machine, for example, having the cutting tool 201 providedwith the curved triangular tip 203 as shown in FIG. 45. Referring toFIG. 46, the holder 204 is positioned so that the longitudinal axisthereof is normal to the surface 208 of the work 207 to be machined andthe intermediate point P_(o) and the portion near the point P_(o) of thecurved cutting edge are entered into the work surface 208. A chip 209produced is flown out along the oblique cutting edge in a twistedcondition and may be wound inside of the rotating work 207.

FIG. 47 is a schematic view for explaining the relationship between theinclination i of the cutting edge 202, i.e. the tip 203, and the actualcutting operation and shows the condition viewed from a point directlyabove the drawing surface in which the cutting edge 202 of the tip 203is entered into the work surface positioned in the same plane as thedrawing surface. Referring to FIG. 47, the inclination i of the cuttingedge is defined by a tangential line m at the point P_(o) of the curvedcutting edge 202, which is linearly shown at an appearance in thiscondition, intersecting a line l normal to the cutting direction V. Inthe example shown in FIG. 47, although there is shown a case where anormal rake angle of the curved cutting edge 202 is zero, FIG. 48 showsa case where the normal rake angle is a certain positive angle α_(n). Inthe latter case shown in FIG. 48, the oblique edged tip 203 is inclinedby the angle α_(n) with respect to a plane normal to the drawingsurface, and the angle α_(n) is generally selected from -6° to +6°, andin a specific case where a grooved recess or inclined rake surface suchas chip breaker or chip former is provided for the rake surface of thecutting edge 202, the angle α_(n) may take an angle of approximately+20°.

FIG. 49 is a graph for showing curves A and B which represent thetheoretical maximum surface roughnesses of the work in case of theconventional cutting tool and the oblique edged tool according to thisinvention respectively.

The following Table 3 shows theoretical equations and numerical valuesfor obtaining the curves shown in FIG. 49.

                  TABLE 3                                                         ______________________________________                                                    Theoretical Equation                                                                          Example of                                        Cutting Tool                                                                              for Surface Roughness                                                                         Numerical Value                                   ______________________________________                                        Conventional cutting tool                                                                  ##STR1##       R.sub.a = 0.8(mm)                                 Cutting tool of this invention                                                             ##STR2##       R.sub.b = 300(mm) i = 45°                  ______________________________________                                    

In the Table 3, f is feed amount (mm/rev.), R_(a) is a radius (mm) ofthe nose of the cutting edge of the conventional tip and R_(b) is aradius of curvature of the curved cutting edge of the oblique edged toolof this invention. With the conventional cutting tool, a tip providedwith a nose having relatively small radius is generally used forsuppressing the generation of undesirable vibrations in the finishingcutting operation and a tip having the nose radius of 0.4˜0.8 mm iswidely used. The curve A in FIG. 49 shows a theoretical surfaceroughness obtained by the use of the conventional tip having the noseradius of 0.8 mm. On the other hand, the curve B in FIG. 49 also shows atheoretical surface roughness obtained by the use of the tip providedwith the curved cutting edge and having the radius of curvature of 300mm and inclined so as to suppress the generation of the chattervibrations. As will be understood from the curves shown in FIG. 49, theoblique edged cutting tool according to this invention can obtain themachined surface roughness superior to that obtained by the conventionalcutting tool throughout the entire feed amount of the tool, andmoreover, the difference between the surface roughnesses obtained bythose tools becomes widened as the feed amount becomes large, whichmeans that the oblique edged tool of this invention is more suitable forhigh feed amount cutting operation to obtain the superior machinedsurface roughness of the work.

FIG. 50 shows one example of the machined surface roughness of the workobtained by the use of the oblique edged tool according to thisinvention under or with conditions shown in the following Table 4.

                  TABLE 4                                                         ______________________________________                                        Items       Cutting Conditions                                                ______________________________________                                        Substance of work                                                                         S 45C                                                                         (Carbon steel for machine structure use)                          Machine tool                                                                              Extension boring and turning mill                                 Cutting speed                                                                             150˜250 m/min.                                              Feed amount 0.4 mm/rev.                                                       Depth of cut                                                                              0.05 mm                                                           Cutting tool (tip)                                                                        Inclination (i) = 45°                                                  Nose radius R = 300 mm                                            ______________________________________                                    

FIG. 51 shows a relationship between the feed amount f (mm/rev.) and themachined surface roughness (R_(max)μm) of the work in a case where theoblique edged tool according to this invention is used under or with thecutting conditions of cutting speed: 150˜250 m/min.; depth of cut: 0.05mm; feed amount: 0.4˜6.3 mm/rev.; dry type cutting; material of a workto be machined: S45C; and used tool: oblique edged tool havinginclination angle of 45° and radius of curvature of 300 mm. In FIG. 51,the theoretical maximum surface roughness and the actual surfaceroughness at the experiment of the machined work are shown. Theconventional cutting tool cannot be used for the finishing surfaceworking with such high feed amount as shown in FIG. 51. However,according to the oblique edged tool of this invention, as shown in FIG.50, the surface roughness of the machined work below R_(max) =5 μm wasobtained with the feed amount of f=0.4 mm/rev. and the measured surfaceroughness approximately to the curve showing the theoretical surfaceroughness was obtained with the expanded feed amount up to f=6.3 mm/rev.as shown in FIG. 51. On this point, with the conventional non-obliqueedged tool, the measured surface roughness worse by several times thanthe theoretical surface roughness will be observed because of thegeneration of chatter vibrations, wearing of the cutting edge,production of burrs, adhesion of chip to the cutting edge or the like.The reasons why the surface roughness obtained by the cutting tool ofthis invention is superior to that obtained by the conventional cuttingtool will be considered hereinbelow, but the most significant reasonresides in the increasing of the effective rake angle originated byinclining the cutting edge of the tool.

FIG. 52 shows a partial perspective view in an enlarged scale of theoblique edged tool in an actual cutting operation according to thisinvention, in which the tip 203 is positioned vertically with its flatsurface being normal to the surface 208 to be machined of the work 207and the curved cutting edge 202 having large radius of curvature cutsthe work surface to obtain the gradually increasing depth of cut, andafter reaching the maximum depth of cut, the work is cut with thegradually decreasing depth of cut thereby to obtain the finely machinedwork surface.

Referring to FIG. 52, the cross section S of a portion of the work to bemachined and the projected section S' of the section S on the planeP_(xz) have shapes each having relatively wide thickness at the centralportion and relatively narrow thickness at the end portions as shown byoblique lines in FIG. 52. The cross section of the chip hassubstantially the same shape as that of the cross section of the cutwork as shown in FIG. 53. The cross section of the chip made of mildcarbon steel exhibits pale white silver color at both end portions anddark blue color at the central portion and this fact means that thetemperature of the chip is relatively low at the end portions andrelatively high at the central portion of the chip. Accordingly, thefact that the end portions of the chip which contact the machined worksurface provide the relatively low temperature means that the machinedwork surface is less thermally deformed or damaged.

Referring to FIG. 52, the work fed at a cutting speed V_(w) towards thecutting edge 202 is cut thereby and the chip 209 cut away is flown outat a speed V_(c) in a direction having an angle ηc which is determinedby the inclination i of the cutting tip. The chip 209 is as a wholeflown away in the inclined direction of the cutting edge 202 of the tip203 with a twisted manner.

FIG. 54 shows a view for explaining relationships between respectiveangles and speeds of the chip 209 and the curved cutting edge 202, andin FIG. 54, the feed amount f shown in FIG. 46 or 52 is eliminated forthe clarification of the explanation and the width of the work 207 isnarrowed less than the width of the cutting edge 202. In addition, thechip 209 is linearly flown out without twisting for clearly showing thechip flowout direction. In FIG. 54, a symbol V_(w) designates a cutspeed of the work 207, V_(c) is a flow-out speed of the chip 209, α_(n)is a normal rake angle, α_(e) is an effective rake angle, and ηc is achip flow-out angle.

In general, when the cutting edge 202 is inclined by an angle i withrespect to the direction normal to the cutting direction, the chipflow-out angle ηc is an angle constituted by a plane normal to thecutting edge 202 and the chip flow-out direction and measured on therake surface of the tip 203, and the following equation is establishedfrom a geometrical view point.

    sinα.sub.e =sinηc·sini+cosηc·cosi·sinα.sub.n ... (6)

In the equation (6), the normal rake angle α_(n) is a rake angle in aplane normal to the cutting edge and the machined surface of the workand is set at the designing time of the cutting tool, and accordingly,the normal rake angle α_(n) is easily measured. The effective rake angleα_(e) is a rake angle in a plane including the cut speed V_(w) and thechip flow-out speed V_(c) and is the most important rake angle for acutting mechanism. With the equation (6), it will be found that theeffective rake angle α_(e) can be calculated when the chip flow-outangle ηc is obtained. In this case, as a result of the experiment, itwas found that the effective rake angle α_(e) is larger than the normalrake angle α_(n) and that a cutting operation can be done with highcutting performance by inclining the cutting edge of the tip even if thecutting tool is itself not provided with a sufficiently large rakeangle.

FIG. 55 is a view for explaining the relationship between the cuttingdirection and the feeding direction of the tip 203 on the point P_(o) ofthe cutting edge 202, and in this figure, only the projected cuttingedge 202 is shown by a solid line. In FIG. 55, in a case where thecutting direction is represented by the arrow V_(w1), the feedingdirection will be chosen to the direction f₁ or f'₁, while representedby the arrow V_(w2), the feeding direction will be chosen to thedirection f₂ or f'₂, thus being convenient for the practical use of thecutting tool.

FIG. 56 is a perspective view showing a work cutting operation in whicha cylindrical work 207 is cut by an oblique edged tool 201 shown in FIG.45. The chip 209 is flown out with the twisted condition along theinclined rake face of the tip 203. As shown in FIG. 56, according to thecutting tool of this invention, the chip 209 is flown away in apredetermined direction without dispersing randomly as observed in theconventional cutting tool, so that the chip can be easily disposed of.

FIG. 57 is a schematic view, similar to FIG. 47, showing a relationshipbetween the inclination i of the cutting edge 202 and the cuttingoperation shown in FIG. 56, as viewed from a point directly above thedrawing surface in which the cutting edge 202 of the tip 203 is enteredinto the work surface positioned in the same plane as the drawingsurface. The inclination i of the cutting edge 202 in FIG. 57 is definedby the same manner as that described in connection with FIG. 47.

Modifications of the embodiment set forth hereinbefore in connectionwith FIGS. 45 through 57 will be described hereunder in conjunction withFIGS. 58 through 61 in which like reference numerals are added toelements or portions corresponding to those of the former embodiment.

FIG. 58 shows a partial perspective view of an oblique edged cuttingtool in which a tip 203c is provided with substantially equilateralsquare configuration and the cutting edge 202 has a radius of largecurvature, and the tip 203c is fitted to a tip mount portion formed inthe front end of the holder 204 in an inclined manner. Although, withthis equilateral square tip 203c, substantially the same cuttingoperation or condition is attained as that described with reference tothe equilateral triangular tip, the numbers of cutting edges areincreased, thus being economical.

FIG. 59 shows a perspective view in which the oblique edged cutting tool201 shown in FIG. 58 cuts the inner surface of the cylindrical work 207.With this cutting operation, the radius R of curvature of the curvedcutting edge 202 will have to be satisfied with the following condition.

FIG. 60 is a partially enlarged plan view of FIG. 59, in which thecurved cutting edge 202 of the tip 203c attached to the holder 204should be selected so as to have an apparent radius R' of curvaturesmaller than the inner diameter of the work 207 to be machined whenviewed from a point directly above the drawing surface. Because thecurved cutting edge 202 is inclined, when viewed from the upper point,the apparent radius R' is smaller than the actual radius R, so that inan acutal operation, any problem will be obviated by selecting the tipprovided with the curved cutting edge having a radius R of curvaturebeing smaller than the inner radius S of the work to be machined.

FIG. 61 shows a partial perspective view of a further modification ofthe oblique edged cutting tool in which a tip 203d is provided withsubstantially hexagonal configuration, the cutting edge 202 has a radiusof large curvature, and the tip 203d is fitted to a tip mount portionformed at the front end of the holder 204 in an inclined manner.Although, with this equilateral hexagonal tip 203d, substantially thesame cutting operation or condition is attained as that of theequilateral square tip, the number of cutting edge is further increased,thus being economical.

According to the embodiments represented by FIGS. 45 through 61 of thisinvention, it will be also easily understood by those skilled in the artthat substantially the same advantages or effects as those (1) through(7) summarized before with respect to the former embodiments representedby FIGS. 20 through 44 can be obtained.

Although not disclosed in detail in the above description, it will beeasily understood that the tip provided with a hole at its centralportion is availably used and the geometric center thereof substantiallyaccords with that of the hole, but is not necessarily limited to the tipof this type according to this invention.

Regarding the embodiments or examples represented by the illustrationsof FIGS. 20 through 60, although the tips might be described as atriangular, square, or equilateral tip, the tip has a curved cuttingedges, as is apparent from the disclosure, and accordingly, the tip maybe called "substantially" triangular, square or equilateral tip.

In the foregoing description of the preferred embodiments according tothis invention, there are referred to oblique edged cutting tools eachcomprising a holder and an indexable throw-away tip provided with curvedouter peripheral surfaces and flat upper and lower surfaces as viewed inthe thickness direction such as shown in FIGS. 22A and 33A. According tothis invention, however, the other tips of the type each provided withflat outer peripheral surfaces and at least one of curved upper andlower surfaces are applicable to the tool holder as describedhereinafter with reference to FIGS. 62 through 75.

For example, FIG. 62 shows a perspective view of a tip 302 having atriangular outer configuration in a plan view, which is provided withthree flat outer peripheral surfaces 303 and a flat lower surface, notnumbered, and the cutting edges 306 are defined as contacting lines ofthe upper edge portions of the peripheral surfaces and the upper curvedsurface, the cutting edges 306 being of course curved outwardly. FIGS.63 shows a modification 302a of the tip 302 which is proviced withcurved upper and lower surfaces in the thickness direction thereof.

As is apparent from FIGS. 62 and 63, the tips 302 and 302a each has athickness gradually reduced from substantially the central portion ofthe upper (and/or lower) surface of the tip towards the apex or cornerportion thereof.

FIG. 64 shows a perspective view of an oblique edged cutting tool ofthis invention provided with the tip of the type shown in FIG. 63 andthe positional relationship of the tip 302a with respect to a toolholder 301 is substantially the same as that described with reference toFIG. 21, so that the detailed description thereabout is now omitted.However, as is apparent from the comparison of FIG. 21 and FIG. 64, theprojecting direction of the cutting edges 106a is different from that ofthe cutting edge 302a, and with this point, the cutting operation orfunction of the cutting tool provided with the tip 302a is performed insubstantially the same manner as that shown in FIG. 45.

Referring to FIG. 64, the effective cutting length of one cutting edgein the feed direction f is l cos i, wherein l is a length of oneperipheral surface of the tip 302a and an angle i is an inclination ofthe cutting edge. In the attached state, an inclination angle ispredetermined to be about 30° to 70° and substantially the centralportion of the cutting edge 306a project outwardly so that the reliefangle is provided in a direction substantially normal to the cuttingedge. This state is identical to that described hereinbefore withreference to the other embodiment such as shown in FIG. 45.

FIGS. 65 and 66 show perspective views of tips of the other type whichare also applicable to the oblique cutting tool of this invention. Thetips 402 and 402a have substantially square outer configurations intheir plan views, and for example, the tip 402 of FIG. 65 is providedwith four flat peripheral surfaces and an upper covered surface 404. Onecutting edge of this tip 402 is constituted by the contacting edge ofone peripheral surface 403 and the curved surface 404 as the curvedcutting edge 406 which project outwardly. A tip 402a has two curvedsurfaces 404a as shown in FIG. 66. The attached state of the tip 402a tothe holder 401 is shown in FIG. 67 as a perspective view, and thecutting operation or function of the holder 401 with the tip 402a issubstantially the same as that described hereinbefore with respect tothe tool shown in FIG. 64, so that the detail thereof is now omitted.

In the case where the tip 302, 302a, 402, or 402a is attached to theoblique cutting tool 301 or 401, as is clearly understood from the planview, the effective cutting length is elongated in comparison with thecase where the tip, shown in FIG. 22a or 33a, having curved peripheralsurface is attached to the holder and the strength thereof in thecutting velocity direction will be improved because the thickness of thetip in this direction is increased.

FIGS. 68 through 75 show perspective views of tips of various types butsimilar to those shown in FIGS. 62, 63, 65 and 66 in their cuttingoperations or functions in the cases where they are attached to theholder in the manner similar to those shown in FIGS. 64 and 67. For thisreason, in the drawings of this application, the examples of the tips ofFIGS. 70 and 72 are only referred to and with the other examples, merelythe perspective views thereof are illustrated with no specific referencenumerals.

The tip shown in FIG. 70 has cutting edges each consisting of curvedportions 506a and a linear portion 506b and the tip shown in FIG. 72 haseight curved cutting edges 606. As is apparent from these examples ofthe tips, according to this invention, tips of various types in shapeand in number of cutting edges can be used effectively.

What is claimed is:
 1. An oblique edged cutting tool for machining awork, comprising:(a) a holder having a front end; (b) an indexablethrow-away tip comprising:(1) a curved surface projecting outwardly; (2)a flat surface; (3) a curved cutting edge defined by a contacting linebetween an edge of said curved surface and an edge of said flat surface;and (4) an outer configuration radially symmetrical about a geometriccenter of said tip; (c) means for releasably securing said tip to saidfront end; and (d) means for positioning said tip at an inclinationangle of from about 30° to about 70° so that said flat surfaceconstitutes a rake face and is positioned substantially normally to asurface of the work to be machined and said curved surface projectsoutwardly from the front end of said holder so that said curved cuttingedge projects forwardly when said tip is secured to said holder; whereinsaid inclination angle is defined as an angle formed by (1) a linetangent to substantially the central portion of an effective cuttingedge portion of said cutting edge and (2) a line normal to a cuttingvelocity direction of said cutting tool and parallel to said worksurface.
 2. The oblique edged cutting tool according to claim 1 whereinthe outer configuration of said flat surface of the tip is radiallysymmetrical about the geometric center thereof, said tip is providedwith at least three outer peripheral surfaces each projecting outwardly,and when said tip is secured to the front end of said holder, said tipis positioned at a relief angle which is defined as an angle formed by(1) a plane coincident with said cutting velocity direction and tangentto said work surface and (2) a line normal to said line tangent to acentral point of the effective cutting edge, said central point formingan apex of said relief angle.
 3. The oblique edged cutting toolaccording to claim 2 wherein said tip has a substantially triangularouter configuration.
 4. The oblique edged cutting tool according toclaim 2 wherein said tip has a substantially square outer configuration.5. The oblique edged cutting tool according to claim 2 wherein saidrelief angle is from about 3° to about 11°.
 6. The oblique edged cuttingtool according to claim 1 wherein the outer configuration of said curvedsurface of the tip has a polygonal shape in a plan view which isradially symmetrical about the geometric center thereof, said tip isprovided with at least three flat outer peripheral surfaces, and saidtip has a thickness reduced from a central portion of said curvedsurface towards apexes of the polygonal shape of said tip.
 7. Theoblique edged cutting tool according to claim 6 wherein said tip isprovided with three flat outer peripheral surfaces.
 8. The oblique edgedcutting tool according to claim 6 wherein said tip is provided with fourflat outer peripheral surfaces.
 9. The oblique edged cutting toolaccording to claim 6 wherein a cutting edge of said tip is constitutedby an edge curved in a thickness direction of the tip.
 10. The obliqueedged cutting tool according to claim 6 wherein a cutting edge of saidtip is constituted by edges curved in a thickness direction and a linearedge located between said curved edges in a continuous manner.
 11. Theoblique edged cutting tool according to claim 1 wherein said tip has anequilateral outer configuration.
 12. The oblique edged cutting toolaccording to claim 1 wherein said tip has a circular outerconfiguration.